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Prochem EVEREST EFI LP Operating Instructions Manual

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Operating Instructions (ENG)
MODELS:
EVEREST EFI LP
EVEREST EFI HP
Read instructions before operating the machine.
980197
AE
04/26/06

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  • Page 1 Operating Instructions (ENG) MODELS: EVEREST EFI LP EVEREST EFI HP Read instructions before operating the machine. 980197 04/26/06...
  • Page 2 MODEL _______________________________________ DATE OF PURCHASE __________________________ SERIAL NUMBER ______________________________ SALES REPRESENTATIVE # _____________________ YOUR DEALER NAME: _________________________________________________________________________________________________ ADDRESS: _______________________________________________________________________________________________ PHONE NUMBER: _________________________________________________________________________________________ Welcome…and congratulations on the purchase of your Mobile Cleaning Unit. This instruction manual is a guide for operating and servicing your unit. Read this manual completely before installing or operating this unit. This unit offers you personal convenience.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Machine Data Log/Overview......1 MAINTENANCE & SERVICE Table of Contents .........2 Receiving Your Unit ........4 Maintenance Maintenance Schedule ......4-1 Key Maintenance Checkpoints ....4-3 HOW TO USE THIS MANUAL Engine.............4-4 Vacuum Pump ........4-5 How to use this Manual........1-1 Water Pump ..........4-6 Vacuum Inlet Filter ........4-6 SAFETY...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS PARTS LIST Framework ..........5-1 Side Panel, Right ........5-5 Side Panel, Left........... 5-7 Chemical Panel........... 5-9 Control Panel ..........5-11 Engine............5-13 Engine Coolant ........... 5-19 Vacuum Blower........... 5-21 Water Pump-PP .......... 5-23 Water Pump-PPHP ........5-25 Vacuum/Heat Exchanger And Silencer..

  • Page 5: Receiving Your Unit

    RECEIVING YOUR UNIT ACCEPTANCE OF SHIPMENT EQUIPMENT LIST: Every part of your cleaning unit was carefully 1. Console. checked, tested, and inspected before it left our manufacturing plant. Upon receiving the unit, 2. Waste tank make the following acceptance check: 3.

  • Page 6: How To Use This Manual

    HOW TO USE THIS MANUAL The SAFETY section contains important information This manual contains the following sections: regarding hazard or unsafe practices of the machine. Levels of hazards is identified that could HOW TO USE THIS MANUAL result in product or personal injury, or severe injury SAFETY resulting in death.

  • Page 7: Safety Instructions

    IMPORTANT SAFETY INSTRUCTIONS When using this machine, basic precautions must always be followed, including the following: READ ALL INSTRUCTIONS BEFORE USING THIS MACHINE. These symbols mean WARNING or CAUTION. Failure to follow warnings and cautions could result in fatality, personal injury to yourself and/or others, or property damage.
  • Page 8 IMPORTANT SAFETY INSTRUCTIONS When using this machine, basic precautions must always be followed, including the following: READ ALL INSTRUCTIONS BEFORE USING THIS MACHINE. These symbols mean WARNING or CAUTION. Failure to follow warnings and cautions could result in fatality, personal injury to yourself and/or others, or property damage.
  • Page 9 DO NOT leave the vehicle engine running while operating this unit. Dangerous Acid, Explosive Gases! Batteries contain sulfuric acid. To prevent acid burns, avoid contact with skin, eyes and clothing. Batteries produce explosive hydrogen gas while being charged. To prevent a fire or explosion, charge batteries only in well ventilated areas.

  • Page 10: Hazard Intensity Level

    HAZARD INTENSITY LEVEL The following WARNING LABELS are found on your cleaning unit . These labels point out important Warnings and Cautions which should be followed at all times. Failure to follow warnings and cautions could result in fatality, personal injury to yourself and/or others, or property damage.

  • Page 11: Technical Specifications

    OPERATIONS TECHNICAL SPECIFICATIONS ITEM DIMENSION/CAPACITY Engine speed 2200 rpm (medium speed) Water Pump ON 900 rpm (idle speed) Water Pump OFF. Water pump rpm 1455 rpm Vacuum pump rpm 3400 rpm Water flow rate 4.5 GPM (maximum) Water pump pressure (low pressure) 1000 PSI (maximum) Water pump pressure (high pressure) 3000 PSI (maximum)

  • Page 12: Installation Requirements

    OPERATIONS FUEL REQUIREMENTS2 . FUEL INSTALLATION REQUIREMENTS REQUIREMENTS DEALER RESPONSIBILITY Use unleaded gasoline ONLY. DO NOT use any gasoline additives. We recommend the use of clean, NOTE: Your distributor from whom you fresh, unleaded gasoline intended for automotive purchased this mobile cleaning unit is use.

  • Page 13: Electronic Fuel Injection System

    OPERATIONS EMISSION CONTROL INFORMATION ELECTRONIC FUEL INJECTION SYSTEM The Zenith Power Products (ZPP) Emission control This unit is equipped with the latest Zenith electronic label is located on the valve head cover of the fuel injection (EFI) technology. The EFI technology engine near the oil fill cap.

  • Page 14: Date Stamp Location

    When referring to an engine for assistance from your Your Everest EFI console was shipped to the dealer dealer, ProChem, or ZPP please identify your with a specific fuel pump and fuel filter. Ensure that engine by the serial # and date code stamped on the ONLY these items are used in the installation of your unit.

  • Page 15: Error Codes

    OPERATIONS ERROR CODES On rare occasions the engine may experience abnormal operation conditions and shut down. Upon shutdown the amber light in the upper right corner of the instrument panel will repeatedly flash an error code to help you determine the root cause of the shutdown. Double-digit numbers are flashed one digit at a time, (i.e. “12” would be shown as “Flash”, pause, “Flash”, “Flash”).

  • Page 16: Zenith Distributor Locations

    OPERATIONS ZENITH DISTRIBUTOR LOCATIONS • CAPITAL ENGINE COMPANY (09046) OH, IN.KY,WV 97 CYPRESS ST. SW PA (WESTERN) REYNOLDSBURG, OHIO 43068 PHONE:740/964-0089 • CULLUM & BROWN, INC. (09045) KS, MO 1607 WABASH PHONE:316/262-5156 WICHITA, KS 67214 800/362-3222 • DIESEL ELECTRIC SERVICE & SUPPLY (09116) 652 W.
  • Page 17 WATER REQUIREMENTS effective in lower concentrations. Hard water deposits will adversely affect the If you require a water softener, PROCHEM has a plumbing and heat exchange systems on this unit. model to meet your needs. Please contact your The map below will give you an idea of where areas nearest distributor for information, price, and of high water hardness may occur.

  • Page 18: Components

    COMPONENTS LOW PRESSURE SOLUTION SOLUTION REGULATOR PRESSURE HIGH PRESSURE 1000-3000 PSI WARM SOLUTION TEMPERATURE CONTROL VALVE CONDENSED OPERATING INSTRUCTIONS STARTING 1. CONNECT WATER HOSES TO WATER INLET CONNECTIONS AND TURN ON WATER SUPPLY. 2. CONNECT CLEANING AND VACUUM HOSES TO THE DESIRED CLEANING TOOL AND CONSOLE. LOW PRESSURE 3.
  • Page 19 COMPONENTS 1. WASTE TANK FULL INDICATOR LIGHT 8. ENGINE SPEED CONTROL This indicator light is activated when the waste This serves to set the engine speed and tank is full. When lit the unit will shutdown operating parameters. The ‘Low’, ‘Medium’ and protecting the equipment from damage.
  • Page 20 COMPONENTS 14. VACUUM INLETS 20. WASTE OUTLET The vacuum inlets serve as connecting point for vacuum hoses. This valve allows the waste tank to be emptied. Turning clockwise opens the valve. 15. SOLUTION OUTLETS NOTE: This valve must be closed during The solution outlets are the connecting point for operation.
  • Page 21 COMPONENTS 26. FLOW METER 29. FLOW SIMULATOR VALVE The flow meter is a gauge to indicate how much This valve allows solution to move through the liquid chemical is being introduced in the water machine and chemical to be injected simulating system.

  • Page 22: Water Pumping And Heat Transfer

    OPERATIONS The third stage of plumbing and heat exchange takes place in the 2nd heater core located in the WATER PUMPING AND HEAT heater box. These hot engine/vacuum exhaust TRANSFER SYSTEM gases are forced through heater core #2 creating the third stage of heat transfer to the cleaning solution.
  • Page 23 OPERATIONS SINGLE SYSTEM WATER FLOW DIAGRAM LOW PRESSURE (WARM) EVEREST EFI 980197 06/30/04 3-13...
  • Page 24 OPERATIONS SINGLE SYSTEM WATER FLOW DIAGRAM LOW PRESSURE (HOT) 3-14 EVEREST EFI 980197 06/30/04...

  • Page 25: Chemical Injection System

    OPERATIONS CHEMICAL INJECTION SYSTEM After reaching the chemical pulse pump the chemicals can either go into a bypass loop to purge The chemical injection system is unique in that it air from the system or the chemical can be directed utilizes the pressure spikes generated by the high- by the chemical selector valve to the metering valve.

  • Page 26: Vacuum System

    OPERATIONS The vacuum pump compresses and heats the VACUUM SYSTEM incoming air. The hot discharged air is forced down stream into a silencer for noise abatement. After The engine turning an air pump generates vacuum. exiting the silencer, this hot air is mixed with hot The air is channeled in one side of the vacuum gases from the engine.

  • Page 27: Pre-Run Inspections

    OPERATION PRE-RUN INSPECTION PRESSURE HOSE Before starting the unit, connect the pressure NOTE: Operation of this unit is simple. However, only trained personnel should proceed. hose(s) to the outlet connection(s) at the front of the unit. Connect the cleaning tool(s) to the pressure hose(s).

  • Page 28: Priming The Chemical Pump

    OPERATIONS PRIMING THE CHEMICAL PUMP NEVER dispose of waste in storm drains, water ways, or on ground 1. Connect water hose to water inlet connection areas. Always dispose of waste in accordance and turn on water supply. with Local, State, and Federal laws. 2.

  • Page 29: Upholstery Cleaning

    OPERATIONS UPHOLSTERY CLEANING OPERATION Upholstery tool, part #78513 The “HP” units are equipped with a water pump and water delivery system that can support pressure- 1. Set engine speed control to “Low/Upholstery” washing operations up to 4.5 gallons per minute at setting to minimize excess heat.

  • Page 30: High Pressure Shutdown

    OPERATIONS HIGH PRESSURE SHUTDOWN & DE-FLOODING OPERATIONS RETURN TO LOW PRESSURE SYSTEM De-flooding operations involve removal of water from carpet and flooring. This differs from normal 1. Adjust High Pressure regulator to set pressure cleaning operations in that no water or solution is at 400 psi.

  • Page 31: Winterizing Your Unit

    OPERATIONS 8. Prime the chemical system with 50/50 anti- WINTERIZING YOUR UNIT freeze/water mix. Insert the chemical inlet and prime discharge tubes into the anti-freeze 1. Shut off the water supply. Disconnect the water container. Turn the chemical valve to PRIME inlet hose from the front of your console.

  • Page 32: Removing Anti-Freeze From Unit

    OPERATIONS 7. Place the chemical prime hose into the REMOVING ANTI-FREEZE FROM approved container. Submerge the chemical THE UNIT inlet hose in water. Turn the chemical valve to the PRIME position until clear water comes 1. Connect one end of the winterizing loop hose through the prime hose, and then remove the to the bottom solution outlet connection.
  • Page 33 NOTES: EVEREST EFI 980197 06/30/04 3-23...

  • Page 34: Maintenance

    MAINTENANCE SERVICE SCHEDULE Engine Daily Check engine oil level. *** Fill to proper level Engine Daily Check coolant level in overflow bottle Spray WD-40 in lubrication cup at front of console for 5 Vacuum Pump Daily sec. Daily Check oil level.** Fill to proper level Water Pump Solution Inlet Tube Strainer Daily...
  • Page 35 MAINTENANCE SERVICE SCHEDULE Vacuum Exhaust Heat Exchanger 500 hrs Inspect cores and remove debris. Water Pump 500 hrs Change oil** Pulley Set Screws & Hub Cap Check for proper torque valves. Re-torque, if Screws, Water Pump Clutch Shaft 500 hrs required**** Bolts Drive Pulley...

  • Page 36: Maintenance Schedule

    MAINTENANCE HEAT EXCHANGER SYSTEM KEY CHECKPOINTS MAINTENANCE The heat exchange system in your unit transfers Note: Initiation of a planned preventative maintenance program will assure that your unit energy between the unwanted heat of the power has optimum performance, a long operating life, plant and the solution supply system of the unit.

  • Page 37: Engine

    MAINTENANCE 3. Re-torque the manifold and exhaust tube nuts, cylinder head bolts, and carburetor attaching DO NOT service this unit while it is running. The nuts after the first 250 hours of use. high-speed mechanical parts as well as high temperature components may result in severe 4.

  • Page 38: Vacuum Pump

    PD will last several times longer than a premium mineral oil. NOTE: AEON PD (Part# 05-008039) is the oil which PROCHEM puts in the vacuum pump at the factory. Topping off or adding petroleum oil to synthetic oil is NOT recommended.

  • Page 39: Water Pump

    MAINTENANCE WATER PUMP Refer to the Water Pump Operation and Service Manual for specific instructions. VACUUM PUMP DRIVE BELTS 1. Check the crankcase oil level daily to assure the To tighten the vacuum pump belts: proper level. Use the illustration as a guide when checking the oil level.

  • Page 40: Water Pump Drive Belt

    MAINTENANCE Y-STRAINER (OUTLET) WATER PUMP DRIVE BELT Inspect the Y-strainer after the first week of running To tighten the water pump belt: the unit by unscrewing the screen and remove any accumulated debris. Inspect the strainer again 1. Loosen the nuts which hold the water pump every 2 weeks.

  • Page 41: Nitrogen Accumulator

    ENGINE COOLANT REPLACEMENT PRESSURE REGULATOR Annually the coolant in the Prochem machine should be replaced. This coolant is an integral part of the Lubricate the o-rings every 50 hours. Use o-ring heating system and needs to be maintained as any lubricant Part #05-008035.

  • Page 42: Check Valve (Solution Outlet)

    MAINTENANCE CHECK VALVE (SOLUTION OUTLET) CHEMICAL PUMP Inspect the check valve whenever doing service on The only repairs which the chemical pump may the chemical pump or if flow problems occur in the require is the replacement of the diaphragm or chemical system: check valves.

  • Page 43: Packing Nut Adjustment (Chemical Metering & Selector Valves)

    MAINTENANCE HIGH PRESSURE REGULATOR PACKING NUT ADJUSTMENT FOR CHEMICAL METERING, FLOW To adjust: SIMULATOR AND CHEMICAL SELECTOR VALVES Examine the packing nut on the chemical metering, flow simulator, and chemical selector valves for proper tension every 200 hours. When turning the knob, there should be a small amount of resistance.

  • Page 44: Troubleshooting

    TROUBLESHOOTING PROBLEM CAUSE SOLUTION Turn the water supply on or up. Check for Water supply is turned off or the float kinks in the water supply hose. Examine the valve is stuck or improperly adjusted. float valve and adjust or replace. Examine the water inlet filter inside the water box.
  • Page 45 TROUBLESHOOTING PROBLEM CAUSE SOLUTION Examine the tubing between the vacuum Waste tank filter or strainer basket is relief valve and the vacuum gauge and plugged. remove any blockage. Vacuum gauge is giving an improper Inspect hose(s), repair or replace. reading. Vacuum hose(s) is damaged, Inspect the gasket.
  • Page 46 TROUBLESHOOTING PROBLEM CAUSE SOLUTION Check the solution pump circuit breaker on Solution pump circuit breaker has the control panel. Press the ciruit breaker been tripped reset button. Examine switch, electrical connections, and Defective electrical connection in wiring. Repair any defective connections. If the console wiring or defective there is power going to the switch but not switch.
  • Page 47 TROUBLESHOOTING PROBLEM CAUSE SOLUTION Starter turns over engine, but Refer to Nissan Engine Operation and Engine is malfunctioning will not start Maintenance Manual. Engine is out of gasoline Add gasoline to the fuel tank. Waste tank is full Empty waste tank. After inspecting the unit to determine the Main or engine circuit breaker on cause of the tripped circuit breaker, press...

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